Prefabricated building structure and panels comprising the same



Aug. 28, 1962 P. 1'. DAY, JR 3,05,277

PREFABRICATED BUILDING STRUCTURE AND PANELS COMPRISING THE SAME Filed March 6, 1959 2 Sheets-Sheet 1 s, gn/Wdh?.

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FIG.

INVENTOR FIG. 9.

PAUL T. DAY, JR.

BY @W1/v7 9 W ATTORNEYS itlnited lteres Patent t 3,t51,277 PREFABRCATED BUHJBLNG STRCTURE AND PANELS QOMPRSENG '1HE SAME Paul 'l'. Day, ltr., Baltimore, Md., assigner to American Metalcore Systems, lne., Baltimore, viidu Filed Mar. 6, 1959, Ser. No. 797,636 7 Caims. (Cl. 139-1) This invention relates to a prefabricated building structure and panels comprising the building structure.

In the erection of structures, such as gasoline service stations, schools, industrial and commercial buildings, and the like, considerable time is required, first, in building the walls and roof and, secondly, finishing the outer face thereof in one of several different ways, e.g., by application of glazed tile or porcelain enamel thereto. As a consequence, construction is time-consuming and the cost of erecting the structure is high. Additionally, where the building is being erected in place of another, considerable inconvenience to business results, for an extended period of time.

lt is an object of the present invention to provide a building structure fabricated of preformed foundation, wall, roof and ceiling panels, the structure being quickly and easily erected in a fraction of the time and at considerably less expense than heretofore required for a cornparable building structure of conventional construction.

Other objects are to provide a prefabricated building structure which is architecturally preiinished prior to erection, eliminating any need for supplementary treatment at the building site, of the Walls, inside or out, by painting, weather-proofing or insulating; to provide a prefabricated building structure of the character described of solid, durable construction which requires an absolute minimum of maintenance care; to provide a prefabricated building structure comprising iireproof and waterproof panels of light-weight metal and/ or plastic construction possessing superior structural strength, one or both faces of which are coated in a manner to present a unit having aesthetic appeal which is able to withstand the elements; to provide prefabricated wall and roof panels adapted to be readily connected to each other and to supporting structure; and to provide a method for preforming wall and roof panels of metal and/or plastic material and preiinishing one or both faces thereof.

Other objects of the invention will be manifest from the following description of the present preferred form of the invention, taken in connection with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a service station illustrating the present invention;

FIG. 2 is a fragmentary perspective view of a panel constructed in accordance with the present invention, a portion thereof being broken away to disclose details of construction;

FIG. 3 is a horizontal sectional View taken through the door frame of the service station illustrated in FIG. l;

FIG. 4 is a horizontal sectional view taken through a column of an overhead door opening of the service station illustrated in FIG. l;

FIG. 5 is a horizontal sectional view taken through a corner section of the service station illustrated in FlG. l;

FIG. 6 is a horizontal sectional view taken through an exterior corner column of an open bay of the service station illustrated in FIG. l;

FIG. 7 is a fragmentary vertical sectional view taken through a wall section of the service station illustrated in FIG. 1;

FIG. 8 is a fragmentary vertical sectional View of a portion of the wall of FIG. 7, showing to advantage the manner of aftixing the exterior wall to a horizontal frame member;

Patented Aug. 28, 1962 FIG. 9 is a horizontal sectional view taken through an exterior corner column below the iloor line of the service station illustrated in FIG. 1, and showing to advantage details of construction; and

FIG. 10 is a fragmentary transverse sectional view of a modified form of panel forming a part of the present invention.

The panels comprising the structure of the present invention in conjunction with a steel framework are designed to furnish a complete and nished building. The Walls are of the curtain-wall type but independent of structural supports between the floor line and roof or higher level iioor supports. The roof panels and wall panels are designed to be carried by the structural framing system, but capable of withstanding all live-loading called for by local building codes. No additional covering or surfacing is required for the roof panels. In addition, the present panels and framework are all light-weight metallic and/ or plastic construction so that they can be easily carried and raised by workmen without the need of mechanical means.

The panel of the present invention serves a multiple function, in that it is employed as a foundation panel, a wall panel, a roof panel, and a rceilinsT panel. The panel includes a central core comprising a corrugated or undulated metallic or plastic sheet 13 of rectangular shape. ln connection with the corrugated sheet 13, there are provided a plurality of edge units 14 extending about the perimeter of the corrugated sheet and connected thereto in any suitable manner. Edge units 14 are formed to provide a central longitudinal recess 1S coextensive with each unit, the lateral margins of said edge units being bent back upon themselves into spaced parallel relationship to form flanges 16 which are uniplanar With the undulating limits of sheet 13. Flanges 16 serve as a mounting surface to which thin metallic or plastic skins 17 are bonded by suitable adhesive to form the faces of the panel. If desired, one or both faces of the panel may be precoated in conventional manner to provide a building structure which is completely prelinished upon assembly of the panels and framework.

In fabricating the structure of the present invention, a plurality of concrete column footings 18 are poured below ground level at predetermined spaced points. A square column setting plate 19 is positioned on each footing and secured thereto by suitable anchoring bolts 20. Foundation panels 21 are placed on their longitudinal edges along adjacent sides of column setting plate 19 below ground level. Extruded, curvilinear corner sections of metallic or plastic construction designated and provided with lateral flanges 23 are adapted to be received in the respective longitudinal edge recesses 15 of angularly disposed adjacent panels 21. Corner sections 22 hold foundation panels 21 together until concrete footings 18 have set. After this, a tubular column 24, preferably square in cross section, is placed in a corner of column setting plate 19 and bolted down. Tubular columns 24 extend upwardly a predetermined distance and are preferably connected by welding or the like at their upper terminals to horizontal structural steel members 2S which, together with tubular members 24, comprise the framework of the structure.

Right angle members 26 are pre-welded to adjacent sides of tubular column 24, an arm of each of said members being iiush with angularly disposed panels 21. Bolts 27 are passed through panels 21 and right angle members 26 to secure panels 21 to the tubular column 24. It will be noted, from FIG. 1, that panels 21 span footings 18 and form a frost wall as well as a connecting base for the wall panels of the structure. In addition, foundation panels 21 serve as a form for pouring a concrete iioor slab 2S at approximately ground level (see FIG. 7). Conventional anchor rods 29 and reenforcing mesh 30 tie slab.28 into foundation panels 2.1.

superimposed on foundation panels 21 are wall panels designated 31 which, as shown in FIG. l, are vertically and horizontally positioned and are of the same construction as foundation panels 21. For joining panels 31 to the upper edge of foundation panels 21, there are provided extruded Spline-type connectors 32 of cross shape, opposite arms of which are adapted for reception in central recesses of edge units 14 of the respective panels. Adjacent panels joined together in edge-to-edge relationship are connected by vertically disposed ilat bar spline type connectors 33 which extend from the edge recess 15 of one panel into the edge recess of the adjacent panel.

As shown in FIG. 7, double Walls may be employed in some parts of the structure, as in the sales and rest rooms of the illustrated service station, the interior wall panels of the double Walls being designated 31. For connecting interior Wall 31 to slab 28, a horizontally disposed inverted T-connector 34 is employed, the stem of which is adapted to be received in the central recess 15 of edge unit 14 of the panel. The uppermost wall panel 31 is provided with an extruded cap connector 35, the terminals of which are bent downwardly to lie contiguous with the face of the panel. An intermediate portion of the connector is likewise bent downwardly into engagement with central recess 15 of an edge unit 14.

In erecting a wall section into which a show window is to be incorporated (see FIG. 7), there are provided closure plates 36 having spaced parallel protrusions 37 which lit into adjacent central recesses 15 of edge unit 14. Angular structural clips 38 pre-Welded to columns 24 are fixed by bolts or other suitable means 39 to plates 36.

Referring again to FIG. 7, it will be seen that the panel of the present invention is also employed as roof panels, as indicated at 40, and are supported on horizontal structural frame member y around the perimeter of the room. Connection between roof panels 40 and wall panels 31 is effected by use of right angle bars 41, a segment of each of which is fixed to a wall panel 31 in any suitable manner. The other segment of each right angle bar is adapted to extend into central recess 15 of edge unit 14 forming a part of roof panel 40. Horizontally disposed at bar spline-type connectors 42, similar in construction to connectors 33, join the edges of adjacent roof panels 40.

In spaced parallel relation to the roof of the structure, there is provided a ceiling comprising a plurality of ceiling panels 43 of the same construction as foundation panels 21, wall panels 31, and roof panels 49. The ceiling is self-supporting across its span by use of right angle bars 41', one segment of which is lixed to the lowermost section of horizontal structural frame member 25, and the other segment of which supports ceiling panels 43 around the perimeter of the room. Adjacent panels are connected in edgetoedge relationship by horizontally disposed ilat bar spline-type connectors 42.

In FIG. 3 there is illustrated the manner of joining vertical exterior and interior wall panels 31 at the locus of a door-frame 44. Tubular columns 24 are located to lie in hush engagement with the inner face of door-frame 44 with a portion of the latter extending beyond the exterior face of the column a distance equal to the thickness of Wall panel 31. One edge of wall panel 31, in which is mounted T-connector 34, lies in abutting engagement with doorfrrame `44 and one face of the panel lies flush with a side of column 24,. The interior wall panel 31 and T-connector 34 are located in abutting engagement with the opposite face of tubular column 24.

In FIG. 4 there is shown still another portion of the structure of the present invention in the vicinity of an overhead door-opening for the service station. Tubular column 24 and wall panel 31 are secured together by a right angle member 45, the segments of which are respectively -secured to the panel and column in suitable fashion. A second right angle member 46 is employed to nish an edge of the panel.

FIG. 5 illustrates a typical exterior corner illustrating the manner in which a curvilinear corner section 22 connects lWall panels 31, which are at right angles to each other. A similar view is shown in FIG. 6 of an exterior column corner in an open bay without Walls wherein nishing angle members `46 are employed to cover edge units 14 of panels 31.

FIG. 8 discloses a closure sheet 47 for boxing in and concealing horizontal structural member 25. This view also illustrates the securernent of wall panels to horizontal structural member 25 by right angle irons 48.

In FIG. l() there is illustrated a slightly modied form of panel including a corrugated sheet 13', edge units 14', and skins 17', which are the Same as elements 13, 14 and 17 of the panel illustrated in FIG. 2. In accordance with this modified form, insulating material 49 is inserted in the channels of the core formed by the corrugations of sheet 13.

The panels of the present invention are manufactured of metal and plastic components joined together to form a unit of optimum strength and durability. In manufacture, corrugated sheet 13 and edge unitsv 14 are fabricated, after which they are bonded to skins 17 by 4suitable adhesives. One or both faces of the panel are then coated, if desired, to provide a building structure which is architecturally pre-finished.

The preformed `and preinished panels of the present invention are designed to eliminate long construction delays and the expense of erecting structural walls to which glazed tile, porcelain, enamel, etc. are applied. The end result is a more rapidly constructed, more economical, ireproof, and durable structure of light-weight metal and plastic construction. When used for commercial or school-type buildings, the interior surface of the panels can be treated the same as the outer face. These panels can, furthermore, -be designed as loadbearing units lby use of reenforcing means. The various connectors employed for joining the panels are of simple construction and manufactured by an extrusion process. They are easily iitted into place and impart strength to the panels as well as serving as a waterstop. Field caulking renders the structure entirely water-tight.

While I have here shown and described preferred embodiments of this invention, it is, nevertheless, to be understood that various changes may be made therein without departing from the spirit and scope of the appended claims.

What I claim is:

l. In a lbuilding structure having spaced, vertical, structural columns and horizontal structural members connecting the upper terminals of the vertical structural columns, 4a prefabricated foundation, wall and roof panel assembly supported by, and secured to, the structural columns and members, each of the panels being of like, rectangular conformation, the edges of the panels having Ylongitudinal recesses extending about the perimeter thereof, adjacent panels being erected vertically in contiguous edge-to-edge or right angle relationship to form the foundation and walls of the structure, and erected horizontally to form the roof of the structure, and connectors interposed in the recesses between adjacent panels for locking the panels together.

2. A prefabricated foundation, wall and roof panel assembly, as set out in claim l, in which the connectors include flat bars interposed between adjacent panels erected in edge-to-edge relationship.

3. A prefabricated foundation, wall and roof panel assembly, as set out in claim l, in which the connectors include curvilinear corner sections, each of which is provided Iwith lateral flanges adapted to be received in the respective longitudinal edge recesses of angularly disposed adjacent foundation and wall panels.

V4. A prefabricated foundation, -wall and roof panel assembly, as set out in claim 1, wherein said connectors include inverted T-shape members, the stem of each of which is adapted to be received in the longitudinal recess of a panel, the outer at portion of each T-shape member lying ush with a structural column.

5. A Prefabricated foundation, Wall and roof panel assembly as set `out in claim 1, in which the connectors include members of cross-shape cross-section, opposite arms of each of which are adapted for reception in the longitudinal recesses of an abutting foundation panel and wall panel.

6. A prefabricated foundation, rwall and roof panel assembly, as set out in claim 1, in which the connectors include right angle bars, a segment of each of which is :fixed to a wall panel, the other segment lthereof extending into the longitudinal edge recess 0f a roof panel.

7. A prefabricated foundation, wall and roof panel assembly, as set out in claim l, in which the connectors include cap members adapted -for engagement with the upper limit of the uppermost wall panels, the lateral terminals of each cap member being bent downwardly to lie `contiguous with the faces of the panel, an intermediate portion of the cap member being likewise bent downwardly into engagement with the longitudinal edge recess of the panel.

References Cited in the file of this patent UNITED STATES PATENTS 1,974,665 Schnetzer et al. Sept. 25, 1934 2,202,850 Guignon June 4, 1940 2,220,596 Bernhardt Nov. 5, 1940 2,252,568 Hulslander Aug. 12, 1941 2,260,058 Sanford Oct. 21, 1941 2,375,910 Forward May 15, 1945 2,495,862 Osborn Jan. 31, 1950 2,535,494 Hult et al. Dec. 26, 1950 2,762,472 Jackson Sept. 11, 1956 2,849,758 Plumley etal. Sept. 2, 1958 2,911,076 Saunders et al. Nov. 3, 1959 FOREIGN PATENTS 1,049,100 France Aug. 12, 1953 

